LAND ROVER FRELANDER 2 2006 Repair Manual

Pos it ion a contai ner t o coll ect t he oil s pill age. Us ing t he s peci al t ool, remove the drive flange.
Speci al Tool (s ): 205-053 Di scard the nut .5.
Installation 1. W ARNING: Make sure t hat a new nut is i nst all ed.
Us ing t he s peci al t ool, i ns t all the drive flange.
Speci al Tool (s ): 205-053 T orque:
130 Nm 1.
2. CAUTION: Make s ure t hat new bolt s are
ins tal led.
• NOTE: Make s ure t hat thes e component s are
ins tal led t o t he noted removal pos it ion.
Ins t al l the drives haft to the act ive on-demand
coupli ng.
T orque: 40 Nm 2.
Inst all t he dri ves haft rear s upport bracket .
T orque: 35 Nm 3.
Check and top-up the acti ve on-demand coupl ing fluid level.
Refer t o: Act ive On-Demand Coupl ing Fi lli ng (205-02 Rear Drive
Axle/Different ial, General Procedures).
4.
Inst all t he exhaus t sys t em.
5.

Refer t o: Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol ,Removal and Ins tall ati on).

Publi s hed: 11-May-2011
Rear Drive Axle/Differential - Drive Pinion Front Bearing
Removal and Inst all ati on
Removal
Rais e and s upport t he vehi cl e.1.
Drai n t he different ial fl uid.
Refer t o: Different ial Drai ni ng and Fil ling (205-02 Rear DriveAxle/Different ial, General Procedures).
2.
Remove t he rear different ial.
Refer t o: Different ial Case (205-02 Rear Drive Axle/Different ial,Removal and Ins tall ati on).
3.
Remove t he different ial cas ing bol ts .4.
Remove t he different ial cas e.5.
Remove and dis card t he different ial case seal .6.

Remove t he crown wheel ass embly.7.
Pos it ion t he different ial ass embl y in a s ui tabl e vice ass hown.8.
9. CAUTION: Make s ure the pi ni on s eal reces s i snot damaged as the s eal is removed.
Us ing t he s peci al t ool remove t he pinion shaft oi l seal .
9.

10. W ARNING: High t orque applicati on.
CAUTION: Do not us e ai r tools or heat to removet he nut (as t his could contami nate t he head bearing).Fail ure t o fol low thi s ins truct ion may res ult i n damaget o t he component.
• NOTE: The s peci al t ool should be turned cl ockwi se toremove the pi ni on s haft nut.
Us ing t he s peci al t ools remove the pi nion s haft nut .
10.
Secure t he different ial cas i ng to the s peci al tool.Pos it ion t he s upport bol t to it s lowes t s et t ing.
11.
12. CAUTION: Twis t ing or damage t o t he cas ingmay occur i f the bas e pl at es t o s upport the jig on thepres s are not used.
Us ing a s ui table pres s remove t he different ial pini ons haft .
12.

Remove and dis card t he pini on s haft col laps ible spacer.13.
Remove t he tai l bearing i nner race.14.
Us ing t he s peci al t ools remove the pi nion s haft t ailbeari ng out er race.15.

16. CAUTION: It is es s ent ial t hat abs olut e cleanl ines s isobs erved when working on the rear different ial. Al ways cover anyopen ori fi ces us ing lint free non-flocking mat eri al t o prevent t hei ngress of foreign matt er. Fail ure t o follow thi s ins truct ion mayres ult damage t o t he component s.
Remove t he different ial from t he s upporti ng tool .Thoroughl y clean t he pinion shaft paying parti cul ar at t ent iont o t he thread.Us ing a s ui table cl eani ng fl uid t horoughly clean t hedifferent ial casi ngs .
16.
Installation
1. CAUTION: Do not clean or l ubricate the newpini on s haft tai l bearing, as it i s s uppl ied coat ed wi th al ow frict ion oil . Fai lure t o fol low t his ins truct ion wi llrequi re t he pini on s haft tai l bearing t o be repl acedbefore t he different ial can be succes s ful ly as s embled.
Secure t he different ial cas i ng to the s peci al tool.Us ing a s ui table pres s and t he special t ooli ns t all the pi nion s haft t ail bearing out er race.
1.
Inst all t he new pini on shaft spacer.2.

Inst all t he pinion s haft t o t he different ial case.Lubricat e the pi nion head beari ng wit hdifferent ial oil .Pos it ion t he s upport bol t to it s highest s et ti ng.
3.
4. CAUTION: Do not clean or l ubricate the newpini on s haft tai l bearing, as it i s s uppl ied coat ed wi th al ow frict ion oil . Fai lure t o fol low t his ins truct ion wi llrequi re t he pini on s haft tai l bearing t o be repl acedbefore t he different ial can be succes s ful ly as s embled.
Us ing a s ui table pres s and t he special t ool i ns t all thepini on s haft tai l bearing i nner race.
4.
Pos it ion t he different ial ass embl y in a s ui tabl evice as s hown.Remove t he different ial from t he s upporti ngt ool .
5.

6. W ARNING: High t orque applicat ion.
• CAUTIONS:
The s peci al tool s hould be t urned count erclockwis e t o ins t al l the pi nion s haft nut.
Do not us e ai r tools to i nst all t he nut. Fail ure t ofol low thi s ins truct ion may res ult i n damage t o thecomponent .
• NOTE: 250 Nm (184 lb.ft) i s t he mi ni mum torquerequi rement to begi n collaps ing t he pini on s haft s pacer.
Us ing t he s peci al t ools i nst all t he new pini onnut.Tight en to 250 Nm (184 ib. ft).
6.
7. CAUTIONS:
Make s ure the specified t orque t o rot ate thepini on s haft is not exceeded. If exces s prel oad isapplied to the joint t he pinion s haft s hould be removedand a new col lapsi ble s pacer, pinion shaft tail beari ng,pini on s haft tai l bearing cup and pinion nut mus t bei ns t alled.
The s peci al tool s hould be rot ated at 60 rpm (1xrevolut ion per s econd) t o produce a cons i st ent reading.
The pi ni on s haft s houl d be rotat ed through t woful l revolut ions by hand before the t orque meas urementi s performed.
Us ing t he s peci al t ool, check t he t orque requiredt o rot ate the pi nion s haft . The specified t orquei s 1.1 Nm +/- 0.2 NmIf the s pecifi ed t orque t o rot ate the pi ni on s hafti s not reached, usi ng t he s pecial t ool s, t ight ent he pinion flange nut in one degree increment sand check t he rot ati onal t orque after each unt ilt he s pecified t orque of 1.1 Nm +/-0.2 Nm i sachi eved.
7.
8. CAUTION: Do not l ubricate the pi ni on oil s eal.
Us ing a s ui table pres s, t he s peci al t ool and adapt eri ns t all the pi nion beari ng oil s eal .
8.Inst all t he crown wheel ass embly.9.

10. CAUTIONS:
Make s ure the mati ng faces are cl ean, fai lure t ofol low thi s ins truct ion may res ult i n damage t o thedifferent ial .
Make s ure the new s eal i s not twi st ed whenfit ti ng, failure t o fol low this ins truct ion may res ult i ndamage t o t he different ial.
Inst all t he different ial cas e s eal.Apply a thi n amount of clean di fferenti al oi l tot he new different ial casi ng s eal .
10.
Inst all t he different ial cas ing bol ts .Tight en the 7 bolt s to 29 Nm.
11.
Inst all t he rear different ial.
Refer t o: Different ial Case (205-02 Rear Drive Axle/Different ial,Removal and Ins tall ati on).
12.
Fil l the di fferenti al cas e wit h flui d.
Refer t o: Different ial Drai ni ng and Fil ling (205-02 Rear DriveAxle/Different ial, General Procedures).
13.